Manufacturer · Fashion & Home Accessories
The quality of plastic buttons is checked by a few clear signs: the same size and thickness, smooth and centred holes without sharp edges, even colour throughout the batch, no bubbles or cracks, and resistance to washing and ironing. Most problems on the sewing floor – broken thread, lost buttons, colour complaints – start with a defect that could have been found with a simple check when the batch was received.
Why button quality matters
A button costs little compared with the garment, but one defective detail can ruin a whole product. If buttons fall off after the first wash, the customer returns the garment and the brand loses trust. If the colour of the buttons differs between two boxes, garments in one order look different. That is why serious garment manufacturers have a simple button inspection procedure – and apply it both to polyester buttons and to all other buttons.
The most common defects and their causes
Sharp edges on the holes
If the holes are not finished properly, a sharp edge remains around them and cuts the thread. The button looks fine but falls off after a few washes. The check is easy: pass a thread through the hole and rub it back and forth – with a defect you will feel roughness or the thread will fray.
Off-centre or uneven holes
Holes off centre or with different diameters make automatic sewing difficult. The button-sewing machine relies on an exact distance between the holes; any deviation leads to broken needles and broken thread.
Differences in size and thickness
Buttons of different thickness in one batch cause feeding problems in the machine and look uneven on the garment. Size is checked with a calliper: 1L = 0.635 mm, so a 20L button should be about 12.7 mm.
Bubbles and inclusions
When the resin is cast, small air bubbles or foreign particles may remain. On the face they are a visible defect, and near the holes they weaken the button.
Brittleness
Incorrectly cured resin or a profile that is too thin makes the button brittle. It breaks during sewing, when pressed on a garment press or when it hits the drum of the washing machine.
Shade differences
Colour differences between individual boxes, or compared with the sample, are usually due to different production batches. That is why it is important for the whole quantity for one collection to come from one batch or to be compared with a reference.
Heat deformation
Thin models can bend or lose their gloss on contact with a very hot iron or press.
Plastic button quality – quick inspection table
| Check | How | Sign of a problem |
|---|---|---|
| Size | Calliper, 10 random buttons | Deviation from the sample |
| Thickness | Calliper | Visibly different buttons |
| Holes | Visual check and thread test | Sharp edge, off-centre |
| Colour | Comparison with the sample in daylight | Different shade or gloss |
| Surface | Inspection under a lamp | Bubbles, scratches, stains |
| Strength | Pressing and bending a few pieces | Cracking or crumbling |
| Heat | Iron test through a cloth | Loss of gloss, deformation |
| Washing | Sewing on and washing in the real process | Colour change, lost buttons |
Procedure when receiving a batch
- Documents – check the model, size, colour and quantity against the order.
- Sampling – take buttons from several different packs, not just one.
- Comparison with the reference – the approved sample is the only objective criterion.
- Technical checks – size, holes, surface.
- Test sewing – on the machine that will be used in production.
- Decision – accept, sort or file a complaint before the buttons enter production.
Sewing on is also part of quality
Even a flawless button falls off if it is sewn on incorrectly. The most common mistakes on the floor are too few stitches, thread that is too thin and over-tightening that leaves no thread shank. Use strong polyester sewing thread and set the machine according to the fabric thickness. With thick fabrics a thread shank is essential, so that the button can sit over the buttonhole without strain.
How to prevent problems at the ordering stage
- Work with a manufacturer that approves a sample before production.
- State in the specification the processes the garment goes through.
- Order the quantity for one collection at once.
- Require batch marking on the packaging.
- Keep a reference sample for every model and colour.
Which defects are acceptable
Not every deviation is a reject. With imitation horn buttons with veining and with imitations of natural materials, variation in the pattern is built into the technology. Minimal differences in gloss between individual pieces are also normal if they cannot be seen from the distance at which the garment is viewed. Critical deviations are those that affect function – size, thickness, holes and strength – and visible differences in the base shade. It is good practice to agree acceptable limits in advance and record them in the specification to avoid disputes at receipt.
What to do if you find a defect
If you find a defect, do not sew the buttons on "at your own risk". Set aside the affected packs, photograph the defect, note the batch number and contact the supplier. Send a few defective pieces and the reference for comparison. The earlier the problem is reported, the easier it is to replace the batch without losing production time.
Quality-controlled polyester buttons from Polkom
Polkom manufactures polyester buttons and delivers them, with more than 30 years of experience in garment accessories. Every made-to-measure order goes through sample approval, and the buttons are delivered labelled and sorted by model and colour. Browse the polyester buttons or send an inquiry – we will help you choose a model suited to your garment and process.
